Check cylinders for leaks

AR01.00-S-1300B

Check cylinders for leaks

01.07.2019

Engine

601 in model 638

1

Cap

2

Charge air hose (engine 601.970)

3

Air intake line (engine 601.942)

4

Oil filler cap

5

Injection nozzle

6.1

Connector

6.2

Connection piece

7

Cylinder leakage tester

 

Remove/install

1

Warm up engine to normal operating temperature

 Coolant temperature approx. 80  °C

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

2

Open engine cooling system cap (1)

3

Check coolant level



AP20.00-D-2010A

 If necessary, add more coolant

4.1

Remove charge air hose (2) from charge air pipe

Engine 601.970

4.2

Remove air intake line (3) from air filter housing

Engine 601.942

5

Unscrew oil filler cap (4)

6

Remove injection nozzles (5)

AR07.03-S-6830A

7

Position piston for cylinder to be checked at ignition TDC

Crank engine at crankshaft

AR01.00-S-0120B

8

Calibrate the cylinder leakage tester (7) and connect it

AR01.00-S-1300-01A

 Observe operating instructions



Check

9

Apply compressed air to cylinder and read off pressure loss at cylinder leakage tester (7)

Permissible pressure loss in total

*BE01.00-N-1001-02A

Permissible pressure losses on valves and cylinder head gasket

*BE01.00-N-1002-02A

Permissible pressure losses to pistons and piston rings

*BE01.00-N-1003-02A

If crankshaft turns



Install retaining lock for crankshaft/starter ring gear

AR03.30-S-5000B

In the event of increased pressure loss, identify the cause.



Determine cylinder pressure loss



AH01.00-N-1300-02A

10

Conduct test for other cylinders in the firing order of the engine



AH01.00-N-0100-01A

 Firing order

11

Remove cylinder leakage tester (7)

12

Install in the reverse order

Check values for cylinder leakage

Number

Designation

Engine 601.942/970

BE01.00-N-1001-02A

Permissible pressure loss in total

%

25

Check values for cylinder leakage

Number

Designation

Engine 601.942/970

BE01.00-N-1002-02A

Permissible pressure losses on valves and cylinder head gasket

%

5

Check values for cylinder leakage

Number

Designation

Engine 601.942/970

BE01.00-N-1003-02A

Permissible pressure losses to pistons and piston rings

%

20